Refractory coating compositions



United States Patent ABSTRACT OF THE DISCLOSURE A coating composition especially suitable for coating of cast iron m6ld stools which comprises a susp ns n o finelydivt'ded'n'tafiscopic refractorysolid particles in an aqueous liquid containing abinder is stabilized with an Xanthomonas hydrophilic colloid.

This invention relates to new and improved refractory coating compositions, and to a process for the preparation thereof. It is especially concerned with compositions suitable for application to ingot mold stools.

Recently, investigations have been conducted to fin d means for supplying and applying a suspended slurry or dispersion of arefractory of 'ded silica powder in aqueous colloidal silica for improving ingot mo s 00] life. The slurry or dispersion is applied to the ingot stool, the mold is placed on the stool, and hot metal is poured into the mold.

When the simple combination of aqueous colloidal silica and silica powder is applied by a coarse spray to the stools,- a hard, dense adherent coating is obtained on the stool which reducesierosion of the stool by the hot metal, thereby extending the productive life of the stool. The siliceous coating also prevents the ingot from sticking to the stool.

Wi.h this simple combination of aqueous colloidal silica and silica powder, it is necessary to agitate the slurry or dispersion continuously to prevent settling of the suspended silica powder. If the silica powder settles in tanks or spray lines, the equipment must be dismantled and cleaned. It is, however, possible to apply such composi: tions to stools by brushing or rolling the composition onto the stools, thereby avoiding the plugging and cleaning problems associated with spray applications, but this approach has obvious limitations for efficient, economic application. Spray equipment employing a pressure tank equipped with an agitator, while more efiicient, requires that all slurry lines be evacuated immediately after use, either to waste or back info the pressure tank to prevent line plugging. This approach becomes complicated in casting operations utilizing frequent short-term stool coating.

Considerable efforts have been expended in finding a suspgyfing agent for keeping the silica powder in relatively stable suspension in the aqueous colloidal silica. In several instances, a suspending agent was found which produced stable suspension, but the siliceous slurry, with the suspending agent therein failed because the resultant composition did not adhere satisfactorily to the stool, particularly where the application was made to a stool hot enough so that the liquid phase of the composition vaporized almost instantaneously upon application.

The reason for this problem is that the suspending when the coating slurry hits the hot stool, lifts the layer and prevents bonding of the coating to the stool. Unless the coating is securely bound to the stool, no protection is conferred. Brush coating of stools with the suspended slurry produces the same problems.

It has been discovered in accordance with the invention, that the use of a particular type of suspending agent in a refractory coating composition comprising a slurry of refractory particles in a liquid containing a binder makes it possible to prepare a stabilized slurry which can be mechanically atomized, and when applied ipatomized form to a solid surface such as a hot in'g'ot'stiiol will build up a hard, dense, adherent layer. The quantity of slurry and the area of coating are easily and accurately controlled, resulting in economic application rates.

Thel suspending agent' employed for the purpose of the inventiofis'axanlhor'r'ionas hydrophilic colloid. Thesaid colloid is a polymer containing mannose, glucose, potassium glucuronate and acetyl in the approximate molar ratio of 2:l:1:l. In such a colloid, the potassium portion can be replaced by several: other cations without substantial change in the property of the said material for the purpose of the invention. The said colloid, which is a high molecular weight, exocellular material, may be prepared by the bacterium, Xanthomonas campestris, NRRL B-l459, by whole culturefermentation of a medium containing 2-5 percent commercial glucose, organic nitrogen source, dipotassium hydmgen phosphate and appropriate trace elements. The incubation time is approximately 96 hours at 28 C., under aerobic conditions.

In preparing the colloid as aforesaid, it is convenient to use corn steep liquor or distillers dry solubles as an organic nitrogen source. It is expedient to grow the culture in two intermediate stages prior to the final inoculation in order to encourage vigorous growth of the bacteria. These stages may be carried out in media having a pH of about 7. In a first stage a transfer from an agar slant to a dilute glucose broth may be made and the bacteria cultured for 24 hours under vigorous agitation and aeration at a temperature of about 30 C. The culture so produced may then be used to inoculate a higher glucose (3%) content broth of larger volume in a second intermediate stage. In this stage the reaction may be permitted to continue for 24 hours under the same conditions as the first stage. The culture so acclimated for use with glucose by the aforementioned first and second stages is then added to the final glucose medium. In the aforesaid method of preparing having 7 molecules of water of crystallization and water. The reaction in the final stage may be satisfactorily carried out for 96 hours at 30 C. with vigorous agitation and aeration. The resulting colloidal material can be recovered by precipitation in methanol of the clarified mixture from the fermentation. The foregoing suspending agent provides much more stable slurries than were provided by other suspending agents such as a causticized mixture of polyacrylic acid and polyacrylamine, a carboxy methyl cellulose and methyl cellulose and the like. The problems heretofore discussed with regard to plugsilicate; sodium silicate, or mixtures thereof with colloidal silica'sol as the binder for the slurries of the invention.

The most preferred binder used to form the slurries of the invention is a colloidal silica sol. These are well-known materials and are commercially available from several sources of supply. A typical group of commercially available silica sols that may be used in the practices of the invention are those silica sols sold under the name "Naicoag. Silica sols of this type are described below in Table I.

TABLE I Silica Sol I II III IV V VI Percent colloidal silica as 8102 -36 31-22 49-50 35 pH .J. 1.. 8.6 10.2 8.6 3.7 9.0 3.5 Viscosity at 77 F. epsj. 20-30 6. 5 Specific Gravity at 68 F..... 1. 09 1. 205 1. 255 1. 06 1. 385 1. 255 Average Surface Area M per gram of S102 330-430 190-270 135-190 135-190 120-150 135-190 Average Particle size millimicrons. 7. 9 11-16 16-22 16-22 20-25 16-22 Densit lbs/U.S. gallon at 68 F. 9. 1 10. 0 10. 5 8.8 11. 6 10. 5

N820 ercent 0. 04 0. 0. 10 0. 05 030 0. 01

1 Less than 5.

1 Less than 10.

ging of spray equipment by the siliceous slurry are avoided when Xanthomonas hydrophilic colloid is employed as the suspending agent.

A typical slurry provided in accordance with the invention has the following general composition:

Ingredients: Percent by weight Finely divided refractory 10-70 Binder including liquid 30-90 Xanthomonas colloid Upto about 2 the total being 100% and the viscosity being 1500 to 4500, preferably 1800-2500, centipoises at 70 C.

A specific example of such a slurry is as follows:

Ingredients: Percent by weight Finely divided fused silica (325 mesh) Silica sol containing 30% SiO, in water 43.2 Ethylene glycol 6.5 Xanthomonas hydrophilic colloid 0.3

dispsersedir'ithe slurries of the inve'iiiio'h preferably consist of at least one siliceous refractory, e.g., vitreous silica, crystalline silica, or water-insoluble metal silicates, such as magnesium silicate, aluminum silicate, zirconium silicate or siliceous clays. There may be employed, however, nonsiliceous refractories, such as alumina and graphite.

These materials are all well-known substances and are all commercially available. Typical aluminum silicates, for example, may include mica, a laminated type of aluminum silicate and mullite, an' orthorhombic aluminum silicate available from the Island of Mull or artificially made by heating andalusite, sillimanite or cyanite. Excellent magnesium silicates are forsterite or talc, while a useful zirconium silicate is zircon. A typical crystalline silica is quartz. The most preferred refractory, discussed in more detail hereinafter, is vitreous silica.

The bigder employed in the slurries of the invention preferably is colloidal silica sol. There may be used, however, aqueous dispersions of aluminum phosphate, ethyl Other silica sols that may be used in addition to those above, may be prepared by using several well-known conventional techniques. A convenient method of making aqueous colloidal silica sols is described in Bird, U.S. Patent 2,244,325, wherein a dilute solution of an alkali metal silicate is passed in contact with a cation exchange resin in hydrogen form, whereby the silicate is converted to a dilute aqueous colloidal silica sol. The dilute sol may be concentrated to solids concentrations which are more economically usable from the standpoint of shipping costs and ultimate process use, by employing the techniques described in either Bechtold et al. U.S. Patent 2,574,902; Broge et al., U.S. Patent 2,680,721; or Alexander et al. U.S. Patent 2,601,235. Another type of silica sol which may be used in the practices of the invention is described in the specification of Reuter, U.S. Patent 2,856,302. While aqueous colloidal silica sols may be used, it will be understood that other forms of colloidal silica may be employed, such as for instances, sols which contain a major portion of polar organic solvents. Said sols may be generically referred to as organo sols, and are typified by the sols described in Marshall U.S. Patent 2,386,247. It is only necessary that the silica particles used can be dispersed colloidally in a hydrophilic substance, such as water or lower alkyl alcohols and other organic compounds possessing relatively high dielectric constants.

In some instances mixtures of water and organic substances compatible with water may be employed as suspending media for the colloidal silica particles. Particulai'ly preferred organic substances are those which lower the freezing point of pure aqueous sols by their admixture with these aqueous silica sols. Such final product sols then are especially useful during the colder months of the year when they must be stored and/or used at relatively low temperature. Amines such as morpholine, diethyl amine, etc., and polyhydroxy organics as ethylene glycol; propylene glycol 1,2; propylene glycol 1,3; glycerrine; etc., are preferred materials in making up silica sols containing these substances as sole silica suspending media or as a portion of a mixture additionally containing water. A preferred sol, winterized against freezing contains 5-50 parts by weight of polyhydroxy compound such as ethylene glycol, 20-85 parts by weight of water and 10- 60 parts by weight of silica. In the practice of the present invention the glycol added to the composition is also employed in amount sufficient to inhibit bacterial decomposition of the Xanthomonas hydrophilic colloid. For this purpose the amount of glycol should be at least 0.5% and preferably at least 1% by weight of the composition.

Regardless of the method employed to produce the colloidal silica sol containing water, polar organic liquids or mixtures of these substances as a continuous suspending phase, it is desirable that said sols contain silica particles which are dense, amorphous, and have an average particle diameter which does not exceed 150 millimicrons. As evidenced by a reading of Table I, all the silica sols contemplated as starting materials have an average particle size diameter well below 150 millimicrons. Preferably, the starting silica sols have an average particle size diameter of from -50 millimicrons. The silica concentration in the sols may be between 0.1% and 60% by weight silica expressed SiO More preferred sols contain from 3.0 to 60% by weight of silica and most preferably 10- 60% by weight.

Other sols which may be employed as binders for the silica refractory are those known as salt-free silica sols. These are particularly preferred when the suspension media of the silica particles in the binder itself is solely a polar organic liquid or a mixture of water and polar organic liquid. Since many of the above described sols usually containalkali metal compounds as stabilizers, they are generally not compatible with organic systems due to the fact that the salts present in the aqueous sol cause gelation or precipitation of the silica particles when the aqueous phases are exchanged for polar organic solvents. This can be avoided by use of salt-free aqueous silica sols as starting materials in preparation of pure organosols or mixtures of water and organic liquids as silica carriers. In order to avoid this gelation efiect, it is necessary that the causative cations be removed from the surface of the colloidally dispersed silica particles and from the liquid phase of the sol. This may be readily accomplished by treating typical silica sols of the type described in Bechtold Y -et al., US. Patent 2,574,902, with a cation exchange resin in the hydrogen form and a strong base anion exchange resin in hydroxide form. This treatment tends to produce a finished aqueous sol in which both the continuous aqueous phase of the sol and the particles of silica are considered salt-free.

Typical commercially available silica sols which may be deionized to produce salt-free silica sols are those which are described in Table I above. These aqueous salt-free silica sols may be either used as such in combination with one or more of the named refractories to constitute a slurry coating material or may be modified whereby the aqueous phase is completely or partially exchanged for a hydrophilic polar liquid such as an alcohol or the alcohol is mixed with aqueous sol in desired proportions. The salt-free pure alcosols or aqueous-alcoholic silica sols may then be easily combined with a refractory and the resultant slurry used to coat the stools.

When the particle sizes of the silica sols described above are within the ranges specified, the silica particles present -in the starting aqueous or organic sol have specific surface areas of at least m. /g., and usually in excess of 100 mF/g. Further, when deionized sols are employed as a binder, they generally have a salt content expressed as Na SO of less than 0.01%.

As mentioned above, the most preferred refractory materials are those generally referred to as vitreous silicas.

These are lassy modifications of silica, obtained by the fusion of selected low temperature crystalline forms, and are frequently referred to as guamwla s. Specific vitreggg digsinclude those partic es made from fused quartz glasses, silicate glasses, silica glasses such as the well-known Vycor materials and fused silica glasses. With respect to all of these materials the thermal expansion coefficients are relatively small in proportion to other refractories such as those of the soda-lime and lead glass types. Generally, they have thermal expansion coefficients smaller than 5 10- cm./cm./ C. Also, the silica content of these granular siliceous refractory materials is generally greater than 96% silica expressed as SiO and may range as high as 99.8% SiO Thus, by the term vitreous silica is meant a refractory comprising a silica glass having a thermal coefficient of expansion and SiO; content within the above range.

The most preferred refractories are those which have the highest purities concomitant with the lowest thermal coefficient of expansion. These properties are particularly possessed by vitreous silicas and more particularly those of the fused silica types. The latter materials have a silica content greater than 97% silica expressed as SiO and a thermal coefficient of expansion not greater than about 6x10- cm./cm./ C.

A typical fused silica of the type described above which is extremely useful in the practice of the invention, having a thermal coefiicient of expansion of about 5 X10 cm./ cm./ C., has the following typical analysis:

The above type silica products are readily prepared by grinding very pure fused silica glasses. Likewise, the borosilicate glasses and Vycor silica glasses may be also ground to produce extremely usef refractories.

The particle size Qf the refractory may vary over a wide range. It is preferred, owever, that the refractory particles be sufficiently small so that a uniform dispersion of refractory and binder may be made. The smaller the particle size the longer a slurry made up of binder and refractory, remains in a homogeneous state. It has been determined that particles ranging in size from 125- mesh to as low as a fraction of a micron may be employed. Preferred refractory materials have an average particle size ranging from 22ft) 500 microns in particle diameter, with particles correspon mg to the lower range diameters being most preferred. Specific vitreous silica substances, marketed under the name, Nalcast fall within the above preferred particle size range and have been employed with much success in preventing erosion of base portions of molds and adherence of same to the formed ingots.

The amount of binder making up a portion of the coating slurry must be such that it is present in an amount sufficient to bind the refractory particles together to thereby form a tightly adherent, continuous and unbroken coating which is securely bonded to the surface of the stool. Without proper amount of binder in relation to refractory, the resultant coating, after application and drying of slurry, exhibits a pancake effect with numerous undesirable holes appearing in the coating, thereby exposing portions of the stool or mold base surface. To achieve this, it has been determined that the slurry is preferably composed of from 10 to 70% by weight of refractory, and from 30 to by weight of binder. Most preferably the slurry contains from 30 to 70% by weight of refractory and from 70 to 30% by weight of binder.

The following examples illustrate preferred embodiments of the invention herein. These examples are merely illustrative and the invention is not limited thereto.

Example I A slurry is prepared by mixing with a Lightnin mixer approximately equal parts by weight of crushed, fused silicai n the form of a line, free flowing powder (Nalcote 870-P) and an aqueous, ethylene-glycol-winterized colloidal silica sol (27%) by weight of silica and 0.35% by weight of the Xanthomonas hydrophilic colloid aforedescribed, the latter percent based on the weight of the slurry. The slurry has an initial viscosity of 2600 cps. Upon standing for 8 to 12 hours, the viscosity drops to about 2400 cps. and remains at this level.

At 0.45% and 0.50% by weight of the Xanthomonas hydrophilic colloid, the final viscosities of the slurry are 3300 and 4000 cps., respectively.

Example II A solid mixture of crushed, fused silica in the form of a fine, free flowing powder (Nalcote 870-1) and 0.8% by weight of the Xanthomonas hydrophilic colloid, previously described, were mixed together. The dry mixture is packaged for shipment. This dry mixture can be used to form the slurries of the invention by adding it to and dispersing it in, with agitation, a colloidal silica sol of the character herein described, e.g., a 30% by weight aqueous colloidal silica sol.

The Xanthomonas hydrophilic colloid, in the proportions aforesaid, provides slurries of the refractory in the colloid silica sol binder of the character required for convenient spray application, particularly spraying in the form of an atomized spray. Other thickening agents, such as carboxy methyl cellulose, alginah'fethyl" cellulose, causticized acrylic acid and acrylamide, causticized acrylic acid, and the like, do not produce similar results in terms of the properties of the slurry. These thickening agents,

while forming a satisfactory initial slurry when used in appropriate concentrations, cause an increase in viscosity of the slurry upon standing to the point where solidification occurs as a single phase or in the lower phase when the slurry separates into upper water component and a lower slurries solid component. The latter characteristics are especially detrimental in spray application wherein the solidification results in plugging of spray lines and equipment.

Other thickening agents, as mentioned, do not provide the same degree of dispersion as a Xanthomonas colloid at a given viscosity level. Xanthomonas colloid, in other words, has thev ability of suspending particles of fused silica for a longer period of time than other agents tested at-dosages that provide the same or equivalent viscosity.

If desired, a microbiocide, such as aqueous formaldehyde may be added to the slurry of the invention.

Example III A slurry as described in Example I is sprayed onto a hot, cast iron stool of a mold in the form of a high pressure atomized spray. The temperature of the hot stool is approximately 500 F. With this method of application, the slurry is broken down to fine particles which dry essentially instantaneously on contact with the hot, ingot stool. The sprayed coating builds up .as a hard, dense, adherent layer of a thickness in the order of inch. Certain areas of the stool may be given a thicker coating than the other areas for additional protection to the area where hot metal impingement is most severe.

The spray equipment preferably is high pressure spray equipment capable of providing at least about 200 p.s.i.g. at the pump discharge. High pressures of this order provide suitable flows with good atomization from an atomizing spray nozzle with refractory compositions of the invention.

The present invention is not concerned with the particular method of applying the refractory composition to the solid surface. The high pressure mechanical atomization method described in Example III is very effective. This process is described and claimed in application Ser. No. 429,918, filed of even date herewith by Edwin T. Sortwell.

Example IV ,jwatenf and 13.0 grams of ethylene glycoh-Theamount ofsilica sol is adjusted to compensate for various amounts of sus endi pg agepts to maintain a 200 gram batch size. vlsit cisilimere'measured with a Model LV Brookfield Viscosimeter at rpm. shear utilizing a Number 4 spindle at about F.

The following suspending agents were evaluated:

Xanthomonas hydrophilic colloid (Kelzan) Carboxymethyl cellulose 68% (CMCT-13D) Hydroxyethyl cellulose (Na'trosol 250 MR) Purified carboxymethyl cellulose (Carboxel M-245) Hydroxypropyl methyl cellulose (Methocel 65 HG-Z) Ammonium alginate (Superloid) Alginic acid (Kelcosol) In Test No. 1, samples were placed in sealed glass jars and vibrated for 4 hours on an Eberbach Shaker at shakes per minute.

In Test No. 2, samples were stored in sealed glass jars under static conditions at room temperature.

In Test No. 3, samples were stored in sealed glass jars under static conditions at room temperature. Periodically, each sample was re-mixed and subjected to viscosity testing.

In Test No. 4, samples were stored in sealed glass jars under static conditions at F. for 24 hours, and permitted to cool to room temperature.

In Test No. 5, samples were sealed in glass jars under static conditions below 10 F. for 24 hours, and permitted to thaw to room temperature.

The results of these tests are shown in the tables:

followin g Compositions prepared with Kelzan and CMC T-13 did not separate into two phases. All other samples separated. Samples prepared with CMC T-13D solidified.

TEST N0. 2

Percent Viscosity, Phase Separation Alter Suspending Agent Suspending cps. Eighteen Hours Agent 0. 22 1,500 None. 0.31 2,600 Do. 0. 7 1,600 Do. 0. 76 2, 600 Do. 0. 3 1, 550 Complete 0. 375 2, 500 Do. 0. 57 1,400 25% after 54 hour, complete alter 18 hours. Do 0. 60 2,430 Do. Methoeei 65HG-2 0. 1, 550 alter 2 hours, complete after 18 hours. Do 0.34 2, 500 Do. Superloid 0.26 1, 500 25% alter hour, complete alter 18 hours. 0. 30 2, 500 Do. 0. 22 1,401) Do. 0.25 2, 700 Do.

Compositions prepared with Kelzan and CMC T-131) did not separate into two phases after 18 hours. All other samples separated. Samples prepared with CMC T-13D solidified.

TEST N0. 3

Percent Initial Viscosity Viscosity suspending Agent Bus- Viscosity, after after Remarks pending cps. 3 hours, 18 hours,

Agent cps. cps.

Kelzan 0. 22 1, 600 1, 500 1, 400 No sliparation, soft, easy to m 0. 31 2, 600 2, 500 2, 400 D0. 0. 7 1, 600 15, 500 Solid. 0. 76 2, 600 Do. Natrosol M11250 0. 3 1, 700 1, 500 1, 700 Complete separation, hard to re-mix. Do 0. 375 2, 600 2, 600 2, 550 Do. Carboxel M-245 0. 57 1, 600 1,470 1, 500 Complete separation, soit,

easy to mix. Do 0. 60 2, 550 2, 450 2, 200 D0. Methocei HG-2 0. 30 1, 600 1, 250 850 Comrfiige separation, hard pac Do 0. 34 2, 500 1, 750 1, 000 Do. Superioid.- 0. 26 1, 620 1, 500 1, 250 Complete separation, soft,

easy to mix. 0.30 2, 600 2, 550 2, 500 D0. 0.22 1, 550 1,450 1,200 Do. 0. 25 2, 600 2, 430 2, 300 Do.

Compositions prepared with Kelzan, Natrosol MR-250. Carboxel M-245, Superloid and Kelcosol did not show much change is viscosity after 18 hours. The viscosities of all other samples changed considerably.

TEST NO. 4

Observations Percent Initial Re-rnlxed suspending Agent suspending Viscosity, Appearance Viscosity Agent cps. After 24 Hours after 42 hours Storage cps.

0. 22 1, 700 thin water layer 1, 300 0. 31 2, 600 Me thin water layer. 2,000 0. 7 1, 600 Solid 0. 76 2, 400 -do 0. 3 1, 650 Complete separation- 800 0.375 2,650 do 1,200 0.57 1,400 ..-.-d0 4,200 0.60 2,550 -d0.-. 0.3 1,750 .d0---- 1,200 0.34 2,400 d0. 1,200 0.26 1,500 d0. 1,850 0.3 2,500 do. 2,900 0.22 1,500 .d0- 1,400 0.25 2,500 .--.do 2,200

I Infinite. Thick paste.

Compositions prepared'with Kelzan and CMC T-l 3D did not separate into two phases. All other samples separated. Kelzan Kelcosol prepared compositions showed little change in viscosity but all others showed a marked change.

TEST NO.

Re-mixed, Percent Initial Appearance Alter Viscosity suspending Agent suspending Viscosity, Thawing flatter Agent cps. Storage, cps.

Kelzan 0. 22 1, 700 Me thin water layer 1, 500 D0 0. 31 2, 600 N0 separation 2, 100 CMC 'Il3D 0. 7 l. 600 N0 separation, solid-.-" CMC T13 0.76 2. 400 do Natrosol MR250. 0. 3 1, 650 Comdplete separation l, 400

Do 0.375 2,650 o Carboxel M-245. 0. 57 1, 400 D0 0. 60 2, 550 Methocel 65H G-2. 0. 3 1, 750 D0 0. 34 2, 400 Superloid. 0. 26 1, 500 D0..- 0. 30 2, 500 Kelcoaol. 0. 22 1, 500 0. 25 2, 500

l Infinite. 3 Thick paste.

Compositions prepared with Kelzan and CMC T-13D did not separate into two phases after thawing. Samples prepared with Kelzan, Natrosol MR-250 and Kelcosol showed little change in viscosity. Samples prepared with CMC T-l 3D solidified.

From the foregoing results it will be seen that the Xanthomonas hydrophilic colloid was the only suspend- In the most preferred method the coating slurr is a i plied to solid sgrfaces, especially metal surfaces, having a temperature ranging from the boiling point of water to 1,000 F., and more preferably from 212 F. to 800 F. Best adherence of the solid coating to stools is achieved by slurry application to the stools at a temperature range of ZOO-500 F. For best results, it has been determined that films should measure in thickness from 0.01 inch to' 3 inch and most preferably from 0.01 inch to A: inch. About $6 inch is a most practical thickness. It is believed that the excellent coating success achieved by use of the above described refractory compositions is their ability to remain stable, to provide particles of the proper physical characteristics for application to solid surfaces and to form a strong ceramic coating. The invention also provides coatings which are resistant to acids, for example, when the coated surfaces are brought into contact with acidic vapours, gases and liquids. The invention is hereby claimed as follows:

1. A coating composition comprising finely-divided suspended in an aqueous liquid containing aw from the class consisting Ofv-COHOMMSOLQQLQUS dis ersions of alu WWW- tures thereo e proportions of said re ractory solid particles and said aqueous liquid containing a binder being within the range of 10% to 70% by weight and to 90% by weight, respectively, said suspension being stabilized by intimate dispersion therewith of a stabilizing amount of Xanthomonas campestris hydrophilic colloid.

2. A .coating composition comprising finely-divided macroscopic refractory solid particles suspended in an aqueous liquid containing a binder from the class consisting of colloidal silica sol, aqueous dispersions of aluminum phosphate, ethyl silicate, sodium silicate and mixtures thereof, the proportions of said refractory solid particles and said aqueous liquid containing a binder being within the range of 10% to 70% by weight and 30% to 90% by weight, respectively, said suspension being stabilized by intimate dispersion therewith of a stabilizing amount of a Xanthomonas campestris hydrophilic colloid, said refractory solid particles having a particle size not larger than 125 mesh, Standard Sieve Series, and said composition having a viscosity of 1500-- 4500 centipoises at 70 F.

3. A composition as claimed in claim 1 which also contains a sufiicient amount of an alkylene glycol to inhibit bacterial action on said Xanthomonas campestris hydrophilic colloid.

4. A composition as claimed in claim 1 in which said liquid comprises an alkylene glycol in sufficient amount to lower the freezing temperature of said composition.

5. A composition as claimed in claim 1 which also contains an alkali sufiicient to render it alkaline to a pH notfexceeding about 10.5.

6. A coating composition comprising finely-divided macroscopic vitreous silica dispersed in an aqueous silica sol having also dispersed therein about 02-10% by weight, based on said composition, of a Xanthamonas campestris hydrophilic colloid suspending agent, the proportions of said finely divided macroscopic vitreous silica and said aqueous silica sol in said composition being within the range of 10% to 70% by weight and 30% to by weight, respectively.

7. A stool coating composition useful in coating of cast iron mold stools comprising finely-divided macroscopic vitreous silica dispersed in an aqueous silica sol having also dispersed therein about 02-10% by weight, based on said composition, of a Xanthomonas campertris hydrophilic colloid suspending agent, said composition having a viscosity in the range of about 1500-2500 c.p.s. at 20 F., the proportions of said finely divided macroscopic vitreous silica and said aqueous silica sol in said composition being within the range of 10% to 70% by weight and 30% to 90% by weight, respectively.

8. A stable coating composition comprising 10-70 weight percent finely-divided macroscopic refractory material dispersed in 30-90 weight percent of an aqueous liquid containing a binder from the class consisting of colloidal silica sol, aqueous dispersions of aluminum phosphate, ethyl silicate, sodium silicate and mixtures thereof, and also having dispersed therein about 0.2- 2.0% by weight, based on the total weight of said composition, of a Xanthomonas campestris hydrophilic colloid suspending agent.

9. A process for forming a protective, adherent on a solid surface which comprises applying to such surface at least one layer of a coating composition comprising finely-divided macroscopic refractory particles dispersed in an aqueous liquid containing a binder from the class consisting of colloidal silica sol, aqueous dispersions of aluminum phosphate, ethyl silicate, sodium silicate and mixtures thereof, and having also dispersed therein a quantity of a Xanthomonas campestris hydrophilic colloid suspending agent sufficient to give a viscosity of 1500-4500 cps. at 70 F., the proportions of said refractory solid particles and said aqueous liquid containing a binder being within the range of 10% to 70% by weight and 30% to 90% by weight, respectively, and vaporizing the liquid phase of said composition to leave a dense, tightly adherent refractory coating on said surface.

10. A process for forming a protective adherent coating on cast iron surfaces which comprises applying to a cast iron surface at least one layer of a coating composition comprising finely-divided macroscopic vitreous silica dispersed in an aqueous silica sol having also dispersed therein a quantity of a Xanthomonas campestris hydrophilic colloid suspending agent sufficient to give a viscosity of 1500-2500 cps. at 70 F., the proportions of said finely divided macroscopic vitreous silica and said aqueous silica sol in said composition being within the range of 10% to 70% by weight and 30% to 90% by weight, respectively, and vaporizing the liquid phase of said composition to leave a dense, tightly adherent siliceous coating on said surface.

11. A process as claimed in claim 9 in which said solid surface to which said coating is applied is a mold surface.

References Cited UNITED STATES PATENTS JULIUS FROME, Primary Examiner.

L. HAYES, Assistant Examiner.

US. Cl. X.-R.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3 ,428 ,464 February 18 1969 Leonard W. Pollard It is certified that error appears in the above identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3, line 9, "polyacrylamine, a" should read polyacrylamide, a causticized polyacrylic acid, Column 4, TABLE I, sixth column, line 8 thereof, ".050" should read O 3O Columns 9 and 10 table for TEST NO. 3 fifth column line 7 thereof, "1 ,500" should read l ,550

Signed and sealed this 21st day of April 1970 (SEAL) Attest:

Edward M. Fletcher, Jr. WILLIAM E. SCHUYLER, I]

Attesting Officer Commissioner of Patent 

